More Changes and Is It Fixed?

We left you in Bend after our quick turnaround in Junction City.  We determined the exact fittings for our generator fuel line and went into Bend the next day and had an 18' new line made up.  While there we, of course, had to find lunch and we did at a small pizza chain called Cibelli's.

Delish!

A neighbor in the RV park who lives in Sisters, actually building a house so is in the park was telling us about a great fishing river nearby, the Metolius, so we decided even if we didn't have time to fish, we'd go over and take a look.  It is quite unique in that it just starts as a spring coming out of the ground.  It was so smoky, we didn't spend any time out there.

This is right at the start

 

We then continued to Burns, Oregon is a big state!  Spent a quick overnight there with a welcome reprieve from the smoke.

Clear skies from our site at Happy Hour

Then it was off early the next morning to push all the way to Picabo, ID.  Part of our push was we had a month long reservation in Ennis over the holiday weekend, and the other is, well, we just want to get eastbound.  We found out diesel is very expensive in the fair state of Idaho, the highest we've seen this whole summer.  

Picabo was a quick overnight as well, as we still had quite away to go to get to Ennis.  The smoke came back as we went east.

Hints of smoke

Smoke!

We arrived in Ennis and told them about our change of plans, instead of a month long stay, we are only staying a week, in fact we weren't going to come up here at all with our revised plans, but we could not find one decent place to stay over the Labor Day weekend, so to Ennis we went.  We are in a primo site in the back which usually has killer views across the Madison River Valley, but we couldn't even see the mountains at all, and the wind almost blew us out of our site.  Yeah, we are even more than ready to leave our beloved Ennis.  

We had several projects, the biggest is trying to solve our generator issues, so installing the fuel line was on the top of our list, but the next day dawned with so much smoke and wind and heat we said we'd postpone it a day and go into Bozeman for several errands and lunch.  We got our Petsmart, Costco, hardware store, grocery store, and even the pottery store visits out of the way and went to one of our favorite places, Dave's Sushi and had a delicious lunch!

Now as you can imagine my frustration with our generator has been building and I have been researching everything I can find about it.  Studying the service manual, conferring with other owners with similar problems, searching the forums and posting for info, and just doing a lot of fretting about it.  It seemed that a few people with similar problems had replaced their control boards and solved the issue.  Even the troubleshooting in the manual had finally got to the point where replacing the board was next on the list.  No one likes to just keep plugging expensive parts in hoping you'll finally hit the right one, but it seemed to be logical that after replacing the fuel filter, air filter, fuel pump, and governor actuator, the control board would be a player.  Researching control boards found that Cummins offers an OEM Onan one for $930, but none were available at this time:-(  More research uncovered a company named Flight Systems that specializes in electronic boards as replacements for many electronic items across the industry and have better warranties than OEM.  I called them and yes they had a board for our gen, and it was $585.  Sounding good.  Now we hadn't replaced the fuel line yet, but I wasn't convinced that was going to be our answer, and the many comments such as having a new control board in hand was probably a better investment than gold made me go ahead and order the board even if we didn't end up using it:-)

What a turnaround in temps, we awoke to 37 degrees and no smoke as the wind had changed!  And after it warmed up a bit, we tackled the new fuel line.  I want to say Jan actually did 95% of the job.  I certainly am blessed to have a small wife with great mechanical aptitude and ability, and is eager to help and get involved in all of our projects.  First thing we found a suitable hole in the firewall between the fuel tank and the front of the coach where the generator lives.

The very convenient hole with the new line through it

I fed the line through and Jan took it from there.  She crawled under and was able to run the new line right along the old line, removing the old and fastening the new at the same time.  It was good we decided on 18' instead of the 15' we originally thought, we ended up having maybe 18" extra!  

The back of the gen, supply, that we replaced on the left, and return on the right.
And the new line in the foreground

And I think just to make us feel a little better, this was happening right behind our site!

Smiling Jan working away underneath

New fuel line connected

New line connected at the tank

Anti-abrasion measures taken, we'll get some more foam

Finished up, crossed our fingers, and since we didn't have any neighbors at the time fired it up.  Started perfectly, and proceeded to run for over an hour when it started stumbling and surging again. Damn!  But conveniently the control board showed up a little while later.  We had to wait awhile to let the gen cool down enough to go back in.  I had even ordered an endoscope that ties into our iPhones, something I had thought about many times previously and it arrived at the same time.  I wanted to look up into the air intake to be sure there were no obstructions, another thing to look at according to my research.

The air intake underneath, and no we didn't find any obstruction

When it cooled off, I went in to replace the board.  

The coolant tank has to be moved out of the way first

This dusty place is where the board lives,
yes, we got it all cleaned up

The new board on the left, the old on the right, the bracket
that it mounts in, and our new endoscope

New board in bracket

At this point we got neighbors, but we did run it for a bit more than an hour with no stumbling, not going to call it fixed yet until we run it for several hours, and that won't be until next week.